Kawasaki D+ series ACFAIL or CPU error

Welcome to the forum........

Please provide more detail:
- What was status before problem occurred.
- What is displayed on teach pendant during bootup.
- What have you tried to fix the problem.
- Have you a recent file save (full controller filesave).

Quote

The robot has not worked for 2-3 years.

It is possible data has been lost/corrupted and also disconnection of devices, boards, harnesses.

Compact flash does not exist on D/D+ Controller, only SRAM upto 4Mb and Flash memory board (1QJ - between 16Mb and 32Mb) board.
1QJ stores AS and SV firmware and SRAM is for user/system data.
Without battery for years, usually lose user/system data.
With no user/system data, Controller should boot up to teach pendant screen, but you say only backlight.

If not been used for 2-3 years, can you guarantee all boards and harnesses are connected inside cabinet?
- Can you post image of inside controller.
- Can you post image of dipswitches on 1RA board

On 1RA board, set dipswitches:

1 and 8 to ON and the rest OFF and reboot Controller.
What does the teach pendant display?
Can you read the filesave on the PC - and attach here or attach the header of the filesave?

Not good......Looks like 1RA board is broken.
Can you connect RS232 lead to connection where PCMCIA is, and open KCWin32.
Set correct com port on PC for connection.
During bootup, is any information displayed?

You sure your PC Comms port is set to Com1?

Set dipswitches:
1,3,5,8 to ON, the rest off and reboot.
- What is displayed and also does front panel lights appear in different state.

It sounds like CPU board is bad, maybe ROM Kernel not functioning correctly.
- Without ROM Kernel, no boot loading is capable.
- Very strange for ROM Kernel to fail (even with low/exhausted battery).

One final test:
- Disconnect all umbilical harness to robot arm.
- Disconnect all connections to 1KP board (X7 and X8) but leave X9 connected.
- Remove 1RA and set dipswitch SW1 to 2 and 3 ON, 1, 4 OFF.
- Install 1RA and set dipswitch SW2 to 1,5,6,7,8 to ON - 2,3,4 OFF.
- Connect RS232 crossover between CN8 on 1RA board and PC.
- Set Com port correct and adjust baudrate to 38400.
- Power on Controller - only RED ERROR LAMP should be on.
- KCWIN should display USR->
- If not, then CPU board damaged beyond repair I think...............

If this is the result, I can put some information together for ROM Kernel, but this would be last resort......but it looks like 1RA is damaged.

If the lights on the Control Panel are not changing, and you cannot get any communication reply/messages from the RS232 serial ports, then as far as I know there is no chance of uploading/downloading any data (including ROM Kernel).

There is a procedure to flush and reformat the 1QJ board and may get the Controller up and running and is:
- Flush and Reformat
- Load in ROM Kernel
- Load in AS Firmware
- Load in SV Firmware
- Load in last file save

I will have to compile some info and tools for you in order to do it, so send me your email in PM (it may take me a couple of days).

However, from what you are writing, I suspect 1RA is non recoverable.

I take it the 'flushing and the ROM Kernel' did not work then......shame.....
So you have a replacement installed, then, how is progress?
- Have you managed to upload your backup and get it up and running?